CN112002547A - Integrally formed inductor and preparation method thereof - Google Patents

Integrally formed inductor and preparation method thereof Download PDF

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Publication number
CN112002547A
CN112002547A CN202010864293.3A CN202010864293A CN112002547A CN 112002547 A CN112002547 A CN 112002547A CN 202010864293 A CN202010864293 A CN 202010864293A CN 112002547 A CN112002547 A CN 112002547A
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Prior art keywords
coil
metal powder
component
powder core
parts
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CN202010864293.3A
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Chinese (zh)
Inventor
李媛媛
李伟健
方玲
柳军涛
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Anhui Bowei New Magnetic Technology Co ltd
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Anhui Bowei New Magnetic Technology Co ltd
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Priority to CN202010864293.3A priority Critical patent/CN112002547A/en
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00Fixed inductances of the signal type 
    • H01F17/04Fixed inductances of the signal type  with magnetic core
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/08Cooling; Ventilating
    • H01F27/22Cooling by heat conduction through solid or powdered fillings
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/2876Cooling
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00Fixed inductances of the signal type 
    • H01F17/04Fixed inductances of the signal type  with magnetic core
    • H01F2017/048Fixed inductances of the signal type  with magnetic core with encapsulating core, e.g. made of resin and magnetic powder

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Coils Or Transformers For Communication (AREA)

Abstract

The invention provides an integrally formed inductor and a preparation method thereof, wherein the preparation method comprises the following steps: embedding the coil in metal powder; die-casting the coil embedded in the metal powder; reinforcing the die-cast coil to obtain a coil with a metal powder core; and spraying a coating layer on the surface of the coil with the metal powder core by using a coating solution. The invention uses the coating solution composed of the component A and the component B to spray the coating on the surface of the inductor, thereby accelerating the heat exchange on the surface of the product, reducing the surface and internal temperature of the product, and reducing a series of problems of performance reduction, aging, product damage and the like caused by heating of the inductor in the use process.

Description

Integrally formed inductor and preparation method thereof
Technical Field
The invention belongs to the field of magnetic electronic components, and particularly relates to an integrally formed inductor and a preparation method thereof.
Background
In the development process of electronic technology, the use of the inductor is more and more extensive, the structure of the inductor is gradually developed towards the trend of small size, thinness, large current, high application frequency and better electromagnetic shielding effect after a series of changes, and the integrally formed inductor has the advantages and becomes the popular research and development field of the current electronic components. However, all electronic components face a common problem, namely heat generation. This is because the components have an equivalent resistance, and according to ohm's law, when current passes through the resistance, power is generated, and the power is necessarily converted into heat, and when the generated heat exceeds the level that the components can bear, the product is likely to age or damage gradually.
Therefore, how to provide an integrally formed inductor with good heat dissipation performance is a problem to be solved urgently by those skilled in the art.
Disclosure of Invention
In order to solve the above problems, the present invention provides a method for manufacturing an integrally formed inductor.
A method for preparing an integrally formed inductor, the method comprising:
embedding the coil in metal powder;
die-casting the coil embedded in the metal powder;
reinforcing the die-cast coil to obtain a coil with a metal powder core;
and spraying a coating layer on the surface of the coil with the metal powder core by using a coating solution.
Preferably, the spraying of the coating layer to the surface of the coil with the metal powder core using the coating solution includes:
encapsulating the terminals at two ends of the coil with the metal powder core;
pouring the coating solution into a spray gun kettle, wherein the caliber of a nozzle of the spray gun is more than 1 mm;
and (3) spraying and then curing the coil surface with the metal powder core by using the spray gun, wherein the spraying environment temperature is higher than 5 ℃, the air relative humidity is less than 80%, the coil surface temperature with the metal powder core is 0-60 ℃, and the distance between the spray gun and the coil with the metal powder core is kept at 20-25 cm.
Preferably, the curing is carried out in a normal-temperature curing mode, and the curing time is more than 30 min.
Preferably, the coating solution comprises component a and component B;
shaking the component A uniformly, adding the component B into the component A, mixing uniformly, and standing to obtain a coating solution;
the weight ratio of the component A to the component B is 20: 1;
the component A comprises the following main components in percentage by weight: 50-60 parts of adhesive, 3-5 parts of silicon carbide, 1-5 parts of titanium dioxide, 1-2 parts of manganese dioxide, 1-5 parts of copper oxide, 3-7 parts of graphite, 2-10 parts of zirconium oxide and 2-8 parts of aluminum oxide;
the component B is an ethylenediamine curing agent.
Preferably, the adhesive is a solution obtained by agglomerating modified colloidal particles treated at a high temperature.
Preferably, the filler of the coating solution is a material having high thermal conductivity and infrared emission.
Preferably, the coating can also be brushed, smeared, rolled, dipped or poured.
Preferably, the inductor includes a coil 1, a metal powder core 2, a terminal 3, and a coating layer.
Preferably, the material of the metal powder core 2 is composed of a soft magnetic iron-based alloy composite powder.
Preferably, the coil 1 is formed by winding an AIW copper wire with the temperature resistance level of more than 200 ℃.
According to the invention, the coating is sprayed on the surface of the inductor by using the coating solution consisting of the component A and the component B, so that the heat exchange on the surface of the product is accelerated, the surface and internal temperature of the product is reduced, and a series of problems of performance reduction, aging, product damage and the like caused by heating of the inductor in the use process are reduced.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and those skilled in the art can also obtain other drawings according to the drawings without creative efforts.
Fig. 1 shows a schematic structural diagram of an integrally formed inductor according to the present invention;
fig. 2 shows a temperature rise curve of the integrated inductor of the present invention.
Reference numerals: 1. a coil; 2. a metal powder core; 3. and a terminal.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The invention provides an integrally formed inductor and a preparation method thereof, which are used for solving the problems that power is generated when current passes through the existing inductor, the power is necessarily converted into heat, and when the generated heat exceeds the level which can be borne by the inductor, the inductor is easy to age and damage.
A method for preparing an integrally formed inductor, the method comprising:
embedding the coil in metal powder;
die-casting the coil embedded in the metal powder;
reinforcing the die-cast coil to obtain a coil with a metal powder core;
and spraying a coating layer on the surface of the coil with the metal powder core by using a coating solution.
Specifically, the spraying of the coating layer on the surface of the coil with the metal powder core by using the coating solution comprises:
encapsulating the terminals at two ends of the coil with the metal powder core to protect the terminals at two ends of the coil with the metal powder core and prevent the coating from being sprayed on the surfaces of the terminals to influence the conductivity of the inductor;
pouring the coating solution into a spray gun kettle, wherein the caliber of a nozzle of the spray gun is more than 1 mm; the nozzle of the exemplary spray gun can be 1.5mm, and the caliber of the spray gun is more than 1mm, so that the serious atomization phenomenon can not be generated when the spray gun is used for spraying the coating, and the phenomenon that the coating loses the radiation cooling performance due to the broken coating particles is avoided;
and (3) spraying and then curing the coil surface with the metal powder core by using the spray gun, wherein the spraying environment temperature is higher than 5 ℃, the air relative humidity is less than 80%, the coil surface temperature with the metal powder core is 0-60 ℃, and the distance between the spray gun and the coil with the metal powder core is kept at 20-25 cm.
Before using the spray gun to carry out the spraying, whether the tight connection of watering can, spray gun and air hose is good needs to be ensured, can adjust required air pressure, the type of spouting of spray gun, spray volume etc. according to demand and atomizing degree when carrying out the spraying simultaneously.
So that the coil surface with the metal powder core forms a coating, which may be 0.15mm thick as an example.
The coating needs to be cured after the coating is sprayed, wherein the curing adopts a normal-temperature curing mode, heating is not needed, the equipment and method cost is reduced, the operation is simple, the use is convenient, and the curing time is more than 30 min.
The coating solution for forming a coating layer on the surface of the coil with the metal powder core comprises a component A and a component B;
since part of the material is precipitated after the component A is placed for a long time, the component A is shaken up, the component A is mixed up, the component B is slowly added into the component A while stirring, the mixture is stirred and mixed evenly and then is placed for 30 minutes, so that the coating solution is obtained, the component A and the component B are stirred and mixed evenly and then need to be placed for 30 minutes for use, and the stirred and mixed coating solution is used up within 8 hours.
Specifically, the component A comprises the following main components in percentage by weight: 50-60 parts of adhesive, 3-5 parts of silicon carbide, 1-5 parts of titanium dioxide, 1-2 parts of manganese dioxide, 1-5 parts of copper oxide, 3-7 parts of graphite, 2-10 parts of zirconium oxide and 2-8 parts of aluminum oxide, wherein the adhesive is a solution formed by coagulation of modified colloidal particles treated at high temperature. The solution formed by condensing the modified colloidal particles after high-temperature treatment is used as the adhesive, so that the coating solution is in a fish scale-shaped structure after being formed into a film, is favorable for heat radiation and special properties such as higher visible light and near infrared light reflectivity, higher thermal infrared emissivity, stability and the like, and also has good physical properties, chemical properties and various complex properties of good constructability.
The component A is a main material, and the component B is an ethylenediamine curing agent. The filler of the coating solution is made of a material with high thermal conductivity and infrared emission. Exemplary fillers may be carbon nanotubes, spinel metal oxides. The fillers can enable the coating solution to present macroscopically smooth and microscopically wavy radiation structure units after film forming, and the structure can greatly increase the heat dissipation area and the conductivity and obviously improve the heat exchange effect. Meanwhile, the spinel metal oxide subjected to electron transition can increase the electron energy level, improve the infrared radiation coefficient of an object and maintain the corresponding excellent performances of thermal stability, heat resistance, high strength, corrosion resistance, wear resistance and the like.
The coating can also be brushed, smeared, rolled, dipped and grouted.
Fig. 1 shows a schematic structural diagram of an integrally formed inductor according to the present invention.
As shown in fig. 1, the invention also provides an integrally formed inductor prepared by the method, wherein the inductor comprises a coil 1, a metal powder core 2, a terminal 3 and a coating.
The coating is a coating which radiates heat away from an object or accelerates heat conduction in an infrared mode, and automatically radiates heat to the air space or the internal space of the object in an infrared wave band with the emissivity of about 0.92 and the infrared wave band of 0.5-13.5 mu m, so that heat exchange is accelerated, the surface and internal temperature of an inductor is reduced, and the heat exchange rate is improved. The surface of the integrally formed inductor is subjected to paint spraying treatment, so that the insulativity and the corrosion resistance of a product are improved, and the temperature rise amplitude of the product in the using process is reduced.
Wherein the metal powder core 2 material is composed of soft magnetic iron-based alloy composite powder. The coil 1 is formed by winding an AIW copper wire with the temperature resistance grade of more than 200 ℃.
The coil with the metal powder core before spraying was tested in comparison to the coil with the metal powder core after spraying the coating, as shown in table 1:
table 1: comparison test data table before and after spraying
Figure BDA0002649214820000051
Note: temperature rise is the actual temperature of the surface of the product-the surface temperature of the product at no load
The coating is cured at normal temperature, so that the cost of equipment and the cost of the method are reduced; the coating mode is multiple and can be selected according to requirements; after spraying, the insulation and corrosion resistance of the product are improved, the surface temperature diffusion of the integrally formed inductor is accelerated more effectively, and the maximum temperature rise of the surface of the product is reduced by about 10 ℃. Effectively reduced integrated into one piece inductance product in the use because the risk that spontaneous heating caused the damage to the inductance.
The coating solution consisting of the component A and the component B is used for spraying the coating on the surface of the inductor, so that the heat exchange on the surface of the product is accelerated, the surface and internal temperature of the product is reduced, and a series of problems of performance reduction, aging, product damage and the like caused by heating of the inductor in the use process are reduced.
Although the present invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some technical features may be equivalently replaced; and such modifications or substitutions do not depart from the spirit and scope of the corresponding technical solutions of the embodiments of the present invention.

Claims (10)

1. A preparation method of an integrally formed inductor is characterized by comprising the following steps:
embedding the coil in metal powder;
die-casting the coil embedded in the metal powder;
reinforcing the coil subjected to die-casting molding to obtain a coil with a metal powder core;
and spraying a coating layer on the surface of the coil with the metal powder core by using a coating solution.
2. The method for manufacturing an integrally formed inductor according to claim 1, wherein the step of spraying the coating on the surface of the coil with the metal powder core comprises:
encapsulating the terminals at two ends of the coil with the metal powder core;
pouring the coating solution into a spray gun kettle, wherein the caliber of a nozzle of the spray gun is more than 1 mm;
and (3) spraying and then curing the coil surface with the metal powder core by using the spray gun, wherein the spraying environment temperature is higher than 5 ℃, the air relative humidity is less than 80%, the coil surface temperature with the metal powder core is 0-60 ℃, and the distance between the spray gun and the coil with the metal powder core is kept at 20-25 cm.
3. The method for manufacturing the integrally formed inductor according to claim 2, wherein the curing is performed in a normal temperature curing manner, and the curing time is longer than 30 min.
4. The method of claim 3, wherein the coating solution comprises component A and component B;
shaking the component A uniformly, adding the component B into the component A, mixing uniformly, and standing to obtain the coating solution;
the weight ratio of the component A to the component B is 20: 1;
the component A comprises the following main components in percentage by weight: 50-60 parts of adhesive, 3-5 parts of silicon carbide, 1-5 parts of titanium dioxide, 1-2 parts of manganese dioxide, 1-5 parts of copper oxide, 3-7 parts of graphite, 2-10 parts of zirconium oxide and 2-8 parts of aluminum oxide;
the component B is an ethylenediamine curing agent.
5. The method according to claim 4, wherein the adhesive is a solution obtained by agglomerating modified colloidal particles treated at a high temperature.
6. The method of claim 3, wherein the filler of the coating solution is a material having high thermal conductivity and infrared emission.
7. The method for manufacturing an integrally formed inductor according to claim 1, wherein the coating layer is formed by brushing, smearing, rolling, dipping or pouring.
8. An integrally formed inductor produced by the method of any one of claims 1 to 7, wherein the inductor comprises a coil (1), a metal powder core (2), terminals (3) and a coating.
9. The integrated inductor according to claim 8, wherein the material of the metal powder core (2) is made of soft magnetic iron-based alloy composite powder.
10. The integrated inductor according to claim 8, wherein the coil (1) is made by winding AIW copper wire with temperature resistance over 200 ℃.
CN202010864293.3A 2020-08-25 2020-08-25 Integrally formed inductor and preparation method thereof Pending CN112002547A (en)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2004153068A (en) * 2002-10-31 2004-05-27 Toko Inc Dust inductor and its manufacturing method
CN201007943Y (en) * 2007-01-23 2008-01-16 恒忻电子(苏州)有限公司 Novel integrated inductance
CN103756389A (en) * 2014-01-10 2014-04-30 山东申安照明科技有限公司 Radiative heat loss cooling coating, preparation method and application thereof
CN104240898A (en) * 2014-09-30 2014-12-24 黄伟嫦 Integrally formed inducer and manufacturing method thereof
CN108250811A (en) * 2018-01-29 2018-07-06 北京志盛威华化工有限公司 A kind of infrared hot energy-saving coatings of high temperature resistant and preparation method thereof

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2004153068A (en) * 2002-10-31 2004-05-27 Toko Inc Dust inductor and its manufacturing method
CN201007943Y (en) * 2007-01-23 2008-01-16 恒忻电子(苏州)有限公司 Novel integrated inductance
CN103756389A (en) * 2014-01-10 2014-04-30 山东申安照明科技有限公司 Radiative heat loss cooling coating, preparation method and application thereof
CN104240898A (en) * 2014-09-30 2014-12-24 黄伟嫦 Integrally formed inducer and manufacturing method thereof
CN108250811A (en) * 2018-01-29 2018-07-06 北京志盛威华化工有限公司 A kind of infrared hot energy-saving coatings of high temperature resistant and preparation method thereof

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